Special Work Steps when Producing a KAFO with a NEURO HiSWING R+ and NEURO HiTRONIC

Mount the system string on the model.

Mind the correct position when placing the lamination dummy for the controller. The arrows must point upwards so that the controller can be installed correctly later.

Locate a suitable position on the lower leg shell of the model where you can attach the lamination dummy for the controller. Use CA activator spray as basis and adhere the lamination dummy with medium-viscous fast-acting adhesive to the dummy for the padding material.

Note: please note the safety data sheet for the fast-acting adhesive.

Mark the spot where the connection cable of the system ankle joint will later be led through the laminate. This spot is about 10cm above the axis screw of the system joint and, depending on the joint version, located either left or right beside the system string.

Mark the spot where the connection cable of the system knee joint will later be led through the laminate. A suitable tool for this is a drift pin. In the case of an anterior lower leg shell, the front hole in the shaping dummy serves as a marking aid (see picture). In the case of a posterior shell, use the back hole for orientation.

This is how correctly placed connection cable lamination dummies look like on a KAFO.
In the following work steps, you can see how the lamination dummies are placed.

Important! Note the article number when placing the lamination dummies for the connection cables.

Adhere the lamination dummies for the connection cables into the wye junction, as shown in the previous step.

Insert the end of the lamination dummy for the connection cable for the controller (SH0985-16) into the lamination dummy for the controller.

Important! Use the entire length of the lamination dummy for the connection cable!

Adhere the wye junction close to the lamination dummy for the controller onto the model.

Use CA activator spray as basis for the spot marked in step 4. Adhere the other end of the lamination dummy for the connection cable (SH0985-15) to this spot with medium-viscous fast-acting adhesive.

Important! Use the entire length of the lamination dummy for the connection cable!

Use CA activator spray as a basis for the spot marked in step 5. Adhere the other end of the lamination dummy for the connection cable (SL0935-17) to this spot with medium-viscous fast-acting adhesive.

Important! Use the entire length of the lamination dummy for the connection cable!

Secure the ends of the lamination dummies for the connection cables, that are still loose, with medium-viscous fast-acting adhesive. Use CA activator spray as a basis.

Position the lamination dummies for the cable length compensation so that they touch the lamination dummies for the connection cables of the system joints (SH0985-15 and SL0935-17). The lamination dummies for the cable length compensation are meant to create space for any excess cable lengths. Use CA activator spray as basis and adhere the lamination dummies for the cable length compensation with medium-viscous fast-acting adhesive to the dummy for the padding material.

Remove the system string. If the model is still wet, insulate it with compression film. Then, pull a PA reinforcement stocking and a PVA film tube over the model. The lamination dummies for the controller and the connection cable are now located under the PVA film tube and are thus part of the model.

Reinforce the orthosis shells. Make sure that the reinforcement layers end close to the lamination dummy for the controller and do not wrinkle. Reinforce strongly above and below the lamination dummy. This additional material is needed for attaching the thread insert. You can find more information on this in the online tutorial Joint Assembly NEURO HiSWING R+.

Cover all lamination dummies with the last layer.

This production technique is specifically adapted to our epoxy resin and hardener.

Important! Please note the processing instructions and the safety data sheet for the epoxy resin and hardener. Precisely stick to the mixture ratio and thoroughly mix resin and hardener.

Allow the fibres to soak thoroughly when laminating and rub out any excess resin.
Leave the model overnight (at least 10 hours) under vacuum at room temperature.

Important! Follow the processing instructions for the epoxy resin here as well.

Use an oscillating saw to saw along the cutting edges in order to remove the orthosis parts from the model. You can see the recommended saw blade in the picture. Thus, you can saw very close to the system joint without damaging it.

For this step, the laminate in the area of the lamination dummy for the controller remains closed. Saw the orthosis shells and remove them from the model. The lamination dummy for the controller and the lamination dummy for the cable length compensation remain on the model for the time being.

Clean the orthosis shells and remove the PVA film tube. Temper the orthosis shells.

Important! Follow the processing instructions for the epoxy resin here as well.

Grind the orthosis shells. At the location where the controller will be mounted, remove the laminate along the edges formed by the lamination dummy for the controller. Be careful when removing the laminate. Slowly approach the ideal fit and periodically check whether the controller already fits into the opening.

Now, expose the connecting point for the connection cable.

Mount the system joints according to the instructions for use of the NEURO HiSWING R+ and NEURO HiTRONIC. You can find illustrated step-by-step-instructions in the online tutorials Joint Assembly NEURO HiSWING R+ and Joint Assembly NEURO HiTRONIC.